Well completion tool



Dec. 24, 1968 SMlTH ET AL 3,417,827

WELL COMPLETION TOOL Filed Jan. 9, 1967 2 Sheets-Sheet 2 v v I I D I I INVENTORS; FRANC/S M Jul/7H PAUL L. 7RMLZJ6ER United States Patent 3,417,827 WELL COMPLETION TOOL Francis M. Smith, Gibsonia, and Paul L. Terwilliger, Fox

Chapel Borough, Pa., assignors to Gulf Research & De-

velopment Company, Pittsburgh, Pa., a corporation of Delaware Filed Jan. 9, 1967, Ser. No. 608,135 8 Claims. (Cl. 1754.52)

ABSTRACT OF THE DISCLOSURE An apparatus mounted on the lower end of two concentric strings of continuous tubing adapted to be wound on a reel. A bundle of electrical control lines extend from the tool upwardly through the innermost string of tubing to recording and operating surface positioned equipment. By signals passing through the electrical control lines and fluids delivered through the tubing, the apparatus during a single run into a well can log the formation, seal fluids entering the casing from perforations through the casing above and below the tool, create multiple perforations, control treating of the formation with treating fluids, permit fluid flow testing of the formation, consolidate formation sands, temporarily or permanently seal performations and record well pressures and temperatures.

This invention resides in an apparatus for treating and testing a well during a single run into the well.

Apparatus heretofore employed for completing wells utilize expensive surface equipment, require a large number of runs into the Well and considerable supervision. In addition it is often necessary to utilize costly drilling muds to fill the borehole thereby guarding against blowouts caused by opening the easing into high pressure formations.

A recent development in well testing is a tool which, during a single run into the well, can jog the formation, perforate a single hole, treat the formation with a limited volume of treating fluid, record the formation pressure and temporarily seal the perforation. This tool is satisfactory for testing purposes but is not adapted to perforate long intervals of formation or deliver the large volumes of treating or sealing fluids which are necessary for the commercial completion of a well.

This invention resides in an apparatus which, during a single run into a well, can log the formation, seal fluids entering the casing from perforations through the casing above and below the tool, create multiple perforations through long formation intervals, control treating of the formation with large volumes of acid, fracturing fluid or other formation treating fluids, permit fluid flow testing of the formation for extended periods, consolidate formation sands, temporarily or permanently seal perforations, and record well pressures and temperatures. The apparatus of this invention is adapted to be supported by a relatively light weight portable structure and controlled by a single operator, thereby eliminating the use of expensive rigs, pulling units, mud programs and large numbers of operating personnel.

In the drawings:

FIGURE 1 is a diagrammatic view in partial vertical section of a well with the treating and testing apparatus of this invention installed therein.

FIGURE 2 is a diagrammatic view in partial vertical section showing the treating and testing apparatus of this invention and a portion of the surface equipment used in the operation of this apparatus.

Referring to FIGURE 1, numeral 2 indicates the borehole of the well with casing 4, as preferred in this inven- 3,417,827 Patented Dec. 24, 1968 tion, extending from the surface of the earth downwardly through various subterranean formations. Cement 6 is placed in the annulus formed between the casing 'and the wall of the borehole 2. A support member 8 is attached to the lower end of a string of continuous tubing 10 which communicates with the hollow body of the support member 8 and extends upwardly through the casing 4 to the surface of the earth. A second string of continuous tubing 12, containing an electrical control bundle 14, is in communication with the hollow body of the support member 8, positioned within the outer string of continuous tubing 10, and extends from the apparatus of this invention upwardly through the casing 4 to the surface of the earth. The electrical control bundle 14 consists of a plurality of electrical control lines 15 which are connected on their lower ends to various electrical components of the apparatus of this invention, extend upwardly through the inner string of tubing 12 and 'are connected on their upper ends to various electrical controls and recording instruments located above the surface of the earth.

An upper inflatable packer element 16 and a lower inflatable packer element 18 are mounted on the outer periphery of the support member 8. Packer ports 20 are formed through the inner surface of the support member 8 and into the inner chamber of each of the inflatable packers. Packer valve seats 22 are formed within the packer ports 20 and packer valves 24 are positioned adjacent the packer valve seats 22. Packer valve actuating rods 26 are attached on their outer ends to the packer valves 24 and on their inner ends to a packer solenoid 28 mounted on the inner surface of the hollow support member 8.

An injection port 30 is formed through the support member 8, between the upper and lower inflatable packers 16, 18. An injection valve seat 32 is formed on the inner surface of the injection port 30 and an injection valve 34 is positioned adjacent the injection valve seat 32. An injection valve actuating rod 36 is positioned within the support member 8, connected on its outer end to the injection valve 34 and on its inner end to an injection solenoid 38 mounted on the inner surface of the support member 8.

A pressure port 40 is formed through the support member 8 between the upper and lower inflatable packers 16, 18. A fluid delivery line 42 is positioned Within the support member 8, attached on its outer end to the pressure port 40 and on its inner end to a pressure signal device 44 mounted on the inner surface of the support member 8.

A plurality of jet charges 46 and a temperature signal device 45 are mounted through the support member between the upper and lower packers 16, 18. A logging tool 47 is mounted on the support member 8 above the upper inflatable packer 16.

The jet charges 46, the injection solenoid 38 and the packer solenoid 28 are controlled and operated by signals delivered from the surface of the earth to electrical control lines 15 which are connected on their lower ends to their respective devices.

Signals are delivered from the pressure signal device 44, the temperature signal device 45, and the logging tool 47 to their respective electrical control lines 15. The signals travel upwardly to the surface of the earth where they are received by temperature, pressure and log recorders, shown in FIGURE 2, which fuction to convert the electrical signals into representative recordings.

Referring to FIGURE 2, a casing valve 54 is installed on the upper end of the casing 4. A lubricator 56, with a packing gland assembly 58 and a pressure bleed-0E valve 60, is attached to the upper end of the casing valve 54 to allow the apparatus of this invention to be removed from the well when the well contains a fluid pressure greater than atmospheric pressure.

As preferred in this invention, an A-frame support structure 64 is mounted over the well with a pulley 62 attached thereto. The two strings of tubing 10, 12 and the electrical control bundle 14 are in communication with the treating and testing apparatus of this invention, extend upwardly through the casing 4, through the casing valve 54, lubricator 56, packing gland assembly 58, over the pulley 62 and are spooled onto a retaining drum 66. The retaining drum 66 is power driven and adapted to deliver or withdraw from the well the two strings of tubing 10, 12 and the electrical control bundle 14 thereby allowing the treating and testing apparatus to traverse various locations within the well. Fluid connections 68 are provided on the drum housing 70 to allow fluid communication between the inner chamber of the support member 8 and various surface positioned vessels and equipment (not shown). Electrical control lines 15 extend from the electrical control bundle 14, to the temperature recorder 72, pressure recorder 73, log recorder 74 and to other electrical control devices (not shown) which operate the electrical components of the apparatus. As preferred in this invention, weight disks 48 are attached to the lower portion of support member 8 to facilitate lowering the apparatus of this invention into a well which has a fluid pressure greater than atmospheric pressure.

In the over-all operation of the apparatus of this invention, the support member containing its various component parts is lowered through the well bore to the bottom of the well. The logging portion of the tool is energized and the well is logged as the apparatus is moved upwardly through the well bore. From the log the operator decides what portions of the well should be completed. As preferred in this invention, a plurality of logs may also be obtained on each well by changing the logging tool and rerunning the apparatus.

After the zones to be completed have been chosen, the apparatus is lowered to a position adjacent one of the zones. A signal is delivered from the surface through electrical control lines to detonate one or more of the jet charges thereby perforating the casing and cement sheath and communicating the adjacent formation with the treating and testing apparatus of this invention. The packers are then inflated, as preferred in this invention, to isolate the perforated interval.

To inflate the packers a signal is delivered through the electrical control line to activate the packer solenoid and open the packer valves. Fluid pumped down the annulus 11 enters the packers through the hollow support member. The packers are filled with fluid and the pressure elevated to the extent fluid seals will be created between the support member and the casing thereby isolating the perforated interval. The packer solenoid is deenergized causing the packer valves to seat and prevent the escape of fluid from within the packers.

Formation fluid entering the well through the perforations cause signals to be delivered from the pressure signal device and the temperature signal device to the surface recorders. Further testing of the entering formation fluids may be achieved by delivering a signal to the injection solenoid which causes the injection valve to open and communicate the formation with the inner chamber of the support member. These formation fluids may flow upwardly through the annulus 11 and be collected in vessels at the surface for further measurement and testing.

In the event the perforated zone does not produce fluids naturally, the injection valve is opened and the formation treated or fractured by injecting fluid down the annulus 11, through the hollow support member, the injection port, the perforations, and into the adjacent formation. After formation treatment, the fluids entering the well are recovered at the surface in the manner previously described.

Should the operator perforate into formations which are unconsolidated and produce large amounts of sand and other formation materials, a sand consolidation material, such as resinous coated glass heads, is injected into the perforations by the procedure described for injecting fluid into the formation. This injected material functions to decrease the amount of solid materials produced from the formation.

After testing it is often desirable to seal the adjacent formation. Permanent sealing of perforations is accomplished with this apparatus by opening the injection valve and pumping suitable permanent sealing material, such as cement or plastics, down the annulus 11, through the hollow support member, injection port, perforations and into the formation. Where it is desirable to protect productive formations from Well fluids during the subsequent completion of other zones in the well, a temporary sealing material, such as a time degrading gelled water or gelled oil, is injected in the manner described for permanently sealing the perforations.

After the operator has completed the zone isolated by the packers, the apparatus may be moved to investigate other zones of interest. To release the apparatus, a signal is delivered to the packer solenoid causing the packer valves to open and thereby release the fluid pressure from within the packer elements. As fluid discharges, the packers contract to a diameter which will allow the free movement of the apparatus. After the tool is moved and positioned adjacent the second zone, the completion procedures described above may be repeated.

Other operations which may be performed with the apparatus of this invention are logging temperature profiles and recording the formation fluid temperature of a plurality of zones. To log a temperature profile, the apparatus is lowered to the bottom of the well and the temperature signal device is energized. The apparatus is slowly moved upwardly through the well and the temperature log is recorded at the surface from signals delivered from the temperature signal device to the temperature recorder. To record the formation fluid temperature of a pluality of individual zones, the apparatus is alternately positioned oppposite each zone and the packers are set to isolate each zone. Formation fluids are produced through the annulus 11, as previously described, until a stabilized formation fluid temperature is recorded.

The concentric strings of tubing and the electrical control bundle of this invention are preferably light weight and sufliciently flexible to be wound on a large diameter drum. It is preferred in this invention that the concentric tubing be made of monel. Stainless steel or other compositions may also be used so long as the resultant tubing is sufliciently flexible to be wound on a drum and has sufficient strength to withstand the pressures that will be created during fracturing and treating operations.

It is preferred that the outermost tubing of this invention should have an inside diameter in the range of 1 /2 to 4 inch and the innermost string of tubing should have an inside diameter in the range of /2 to /8 inch. The utilization of small size tubing, as described above, reduces the weight and permits the use of more simplified'supporting structure. Small diameter tubings are also more easily wound on a retaining drum. Additionally it is preferred that both strings of tubing should be substantially jointless continuous tubing. Such tubing is adapted to be more uniformly wound on a drum and is stronger than tubing strings which contain a plurality of joints.

A problem encountered in constructing a dual tubingelectrical conduit structure, such as used in this invention, is the difficulty of inserting long lengths of electrical conduit and tubing. We have found this problem is considerably reduced if the bearing surfaces are first coated with a friction-reducing material such as Teflon. It is therefore preferred in this invention that the electrical conduit, the innermost string of tubing and the inner wall of the largest string of tubing should be coated with Teflon, or other friction reducing material, prior to insertion.

The treating and testing operations that may be performed with the apparatus of this invention have been described generally as a sequence. It is not however intended that all these functions must be performed during a single run into the well. Conversely, the tool may be used to perform a single function or any plurality of functions desired by the operator. It is also intended that the apparatus of this invention may be constructed to contain an infinite number of jet charges. The number of perforating means mounted on the tool is limited only by the space available between packer elements after the desired distance between packers has been selected.

The completion apparatus of this invention can thereby function to log the formation and complete a plurality, of selected zones with only one run into the Well. The treating capabilities of this apparatus allows an infinitely large volume of various fluids to be injected from the surface of the earth into the formation while retaining a maximum amount of control during the treating operation. This apparatus also allows the operator to make a wide range of temperature and pressure surveys. The savings of time, equipment, supervision and completion muds are significant when using the apparatus of this invention.

Therefore we claim:

1. Apparatus for performing services in a well comprising:

a hollow support member having an injection port formed therethrough;

spaced inflatable packer elements, having packer ports formed therethrough, mounted on the outer periphery of the hollow support member and positioned above and below the injection port;

a first continuous tubing extending from the surface of the earth downwardly through the well, attached to the hollow support member and in communication with the inner chamber of the hollow support member;

a second continuous tubing extending from the surface of the earth downwardly within said first continuous tubing and in communication with the inner chamber of the hollow support member;

means for injecting a fluid into the annulus formed between the first continuous tubing and the second continuous tubing;

valve means for controlling the flow of fluid through the packer ports of the inflatable packer elements;

sensing means within the hollow support member;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the valve means for activating said valve means; and

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the sensing means for delivery of signals to the surface.

2. Apparatus for performing services in a well comprising:

a hollow support member having an injection port formed therethrough;

spaced inflatable packer elements, having packer ports formed therethrough, mounted on the outer periphery of the hollow support member and positioned above and below the injection port;

a first continuous tubing extending from the surface of the earth downwardly through the well, attached to the hollow support member and in communication with the inner chamber of the hollow support member;

a second continuous tubing extending from the surface of the earth downwardly within said first continuous tubing and in communication with the inner chamber of the hollow support member;

means for injecting a fluid into the annulus formed between the first continuous tubing and the second continuous tubing;

valve means for controlling the flow of fluid through the packer ports of the inflatable packer elements; valve means for controlling the flow of fluid through the injection port;

sensing means within the hollow support member;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the valve means for activating said valve means;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the sensing means for delivery of signals from the sensing means to the surface.

3. Apparatus for treating and testing a Well comprising:

a hollow support member having an injection port and a pressure port formed therethrough;

an upper inflatable packer element, having a packer port formed therethrough, mounted on the outer periphery of the hollow support member and positioned above the injection port and the pressure port;

a lower inflatable packer element, having a packer port formed therethrough, mounted on the outer periphery of the hollow support member and positioned below the injection port and the pressure port;

a first continuous tubing extending from the surface of the earth downwardly through the well, attached to the hollow support member and in communication with the inner chamber of the hollow support memher;

a second continuous tubing extending from the surface of the earth downwardly within said first continuous tubing and in communication with the inner chamber of the hollow support member;

means for injecting a fluid into the annulus formed between the first continuous tubing and the second continuous tubing;

an upper packer valve adjacent the packer port of the upper inflatable packer for controlling the flow 0f fluid through the packer port;

a lower packer valve adjacent the packer port of the lower inflatable packer for controlling the flow of fluid through the packer port;

a packer solenoid mounted on the hollow support member and attached to the upper and the lower packer valves for operating said packer valves;

an injection valve adjacent the injection port for controlling the flow of fluid through the injection port;

an injection solenoid mounted on the hollow support member and attached to the injection valve for operating said injection valve;

a pressure signal device mounted on the hollow support member and connected to the pressure port;

a temperature signal device mounted on the hollow support member;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the packer solenoid and the injection valve solenoid to operate said solenoids by a signal delivered from the surface;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the temperature signal device and the pressure signal device for delivering a temperature indicating signal and a pressure indicating signal to the surface.

4. Apparatus as set forth in claim 3 wherein the first and the second continuous tubing are monel tubing.

5. Apparatus for treating and testing a well comprising:

a hollow support member having an injection port and a pressure port formed therethrough;

a logging tool mounted on the hollow support member;

a pressure signal device mounted on the hollow support member and attached to the pressure port;

an upper inflatable packer, with a packer port formedtherethrough, mounted on the outer periphery of the hollow support member above the pressure port and the injection port;

a lower inflatable packer, with a packer port formed therethrough, mounted on the outer periphery of the hollow support member below the pressure port and the injection port;

a packer valve adjacent the packer port of the upper inflatable packer;

a packer valve adjacent the packer port of the lower inflatable packer;

a packer solenoid mounted on the hollow support member and attached to the packer valves to control the flow of fluid through the packer ports;

a first continuous tubing extending from the surface of the earth downwardly through the well, attached to the hollow support member and in communication with the inner chamber of the hollow support member;

a second continuous tubing extending from the surface of the earth downwardly within said first continuous tubing and in communication with the inner chamber of the hollow support member thereby forming a path for the flow of fluid from the surface through the annulus formed between the first and the second continuous tubing strings;

electrical control lines extending from the surface of the earth downwardly through the second continuous tubing and connected to the packer solenoid, the injection valve solenoid and the jet charge to operate said solenoids and jet charge by a signal delivered from the surface;

a temperature recorder;

a pressure recorder;

a log recorder;

electrical control lines connected on their upper end to the temperature recorder, pressure recorder and the log recorder, extending downwardly through the second continuous tubing and connected on their lower end to the temperature signal device, pressure signal device and logging tool for delivering signals from the signal devices and the logging tool to said surface recorders.

6. Apparatus as set forth in claim wherein there are a plurality of jet charges mounted on the hollow support member.

7. Apparatus for treating and testing a well comprising:

a first continuous monel internally Teflon coated tubing extending from the surface of the earth downwardly through the well for delivery of fluids therethrough; I

a second continuous monel Teflon coated tubing, concentrically positioned within said first continuous tubing and extending from the surface of the earth downwardly through the well;

a hollow support means having an injection port and a pressure sensing port formed therethrough attached to the first continuous string of tubing and in communication with the first and the second continuous tubing strings;

plurality of externally Teflon coated electrical control lines extending from the surface downwardly through the second continuous tubing and into the hollow support member;

an upper inflatable packer element mounted on the outer periphery of the support member and having an opening in communication with the inner chamber of the hollow support member for the passage of fluid therethrough;

a lower inflatable packer element mounted on the outer periphery of the support member and having an opening in communication with the inner chamber of the hollow support member for the passage of fluid therethrough;

a packer solenoid mounted on the support member, attached to an electrical control wire line and adapted to be actuated by a signal delivered from the surface;

an upper packer valve positioned within the upper packer opening and operated by the packer solenoid to control the flow of fluid through the upper packer opening;

a lower packer val-ve positioned within the lower packer opening and operated by the packer solenoid to control the flow of fluid through the lower packer opening;

an injection solenoid mounted within the hollow support member, attached to an electrical control line and actuated by a signal delivered from the surface;

an injection valve positioned adjacent the injection port and operated by the injection solenoid to control the flow of fluid through the injection port;

a pressure signal device mounted on the support member,

attached to the pressure sensing port, connected to an electrical control line and adapted to deliver a pressure indicating signal to the surface;

a pressure recorder attached to an electrical control line and adapted to receive the pressure indicating signal, and record the pressure corresponding to the signal received from the pressure signal device;

a temperature signal device mounted on the support member, connected to an electrical control line and adapted to deliver a temperature indicating signal to the surface;

a temperature recorder attached to an electrical control line and adapted to receive the temperature indicating signal, and record the temperature corresponding to the signal received from the temperature signal device;

a logging tool mounted on the support member and connected to an electrical control line and adapted to deliver a signal to the surface;

a logging recorder attached to an electrical control line and adapted to receive the signal delivered from the logging tool and record a log corresponding to the logging signal received;

a plurality of jet charges installed through the support member, connected to separate control lines and adapted to be detonated by a signal delivered from the surface.

8. Apparatus as set forth in claim 7 wherein the first and second continuous tubing strings and the electrical control lines are adapted to be Wound on a drum at the surface.

References Cited UNITED STATES PATENTS 2,029,491 2/1936 Lane 4.52 X 2,107,655 2/1938 Vogt 166127 2,633,200 3/1953 Humason 166-127 2,760,581 8/1956 Johnston 166128 3,032,108 5/1962 Bielstein 175-452 US. Cl. X.R. 

